Various methods and apparatuses for multi-stage synthesis gas generation

ABSTRACT

A multiple stage synthesis gas generation system is disclosed including a high radiant heat flux reactor, a gasifier reactor control system, and a Steam Methane Reformer (SMR) reactor. The SMR reactor is in parallel and cooperates with the high radiant heat flux reactor to produce a high quality syngas mixture for MeOH synthesis. The resultant products from the two reactors may be used for the MeOH synthesis. The SMR provides hydrogen rich syngas to be mixed with the potentially carbon monoxide rich syngas from the high radiant heat flux reactor. The combination of syngas component streams from the two reactors can provide the required hydrogen to carbon monoxide ratio for methanol synthesis. The SMR reactor control system and a gasifier reactor control system interact to produce a high quality syngas mixture for the MeOH synthesis.

RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/429,794 filed Mar. 26, 2012, which applicationclaims the benefit of and is a continuation in part of U.S. applicationSer. No. 13/254,020, filed Aug. 31, 2011 and entitled “VARIOUS METHODSAND APPARATUSES FOR AN ULTRA-HIGH HEAT FLUX CHEMICAL REACTOR” whichclaims the benefit of and was a U.S. national stage application under 35USC §371 of PCT Application number PCT/US10/59564, filed Dec. 8, 2010and entitled “VARIOUS METHODS AND APPARATUSES FOR AN ULTRA-HIGH HEATFLUX CHEMICAL REACTOR,” which claims the benefit of both 1) patentapplication Ser. No. 12/795947, filed Jun. 8, 2010 and entitled “SYSTEMSAND METHODS FOR AN INDIRECT RADIATION DRIVEN GASIFIER REACTOR & RECEIVERCONFIGURATION,” which claims the benefit of both U.S. Provisional PatentApplication Ser. No. 61/248,282, filed Oct. 2, 2009 and entitled“Various Methods and Apparatuses for Sun Driven Processes,” and U.S.Provisional Patent Application Ser. No. 61/185,492, titled “VARIOUSMETHODS AND APPARATUSES FOR SOLAR-THERMAL GASIFICATION OF BIOMASS TOPRODUCE SYNTHESIS GAS” filed Jun. 9, 2009, and 2) U.S. ProvisionalPatent Application Ser. No. 61/380116, filed Sep. 3, 2010 and entitled“HIGH HEAT FLUX CHEMICAL REACTOR.”

BACKGROUND

Natural gas or liquid propane gas (LPG) may be used with steam in asteam methane reforming (SMR) reaction. Methanol is a chemical withformula CH3OH (often abbreviated MeOH). It is the simplest alcohol, andis a flammable fuel and can be stored as a liquid at normaltemperatures. Methanol can be synthesized from syngas and then turnedinto gasoline using a Methanol-to-Gasoline process. Biomass may begasified in a gasifier. However, when ashes and other solid particlesfrom a gasifier are sent to a SMR, then that process tends to plug upthe SMR.

SUMMARY

A multiple stage synthesis gas generation system is disclosed includinga high radiant heat flux reactor, a gasifier reactor control system, anda Steam Methane Reformer (SMR) reactor. The SMR reactor is in paralleland cooperates with the high radiant heat flux reactor to produce a highquality syngas mixture for MeOH synthesis. The resultant products fromthe two reactors may be used for the MeOH synthesis. The SMR provideshydrogen rich syngas to be mixed with the potentially carbon monoxiderich syngas from the high radiant heat flux reactor. The combination ofsyngas component streams from the two reactors can provide the requiredhydrogen to carbon monoxide ratio for methanol synthesis. The SMRreactor control system and a gasifier reactor control system interact toproduce a high quality syngas mixture for the MeOH synthesis.

BRIEF DESCRIPTION OF THE DRAWINGS

The multiple drawings refer to the example embodiments of the invention.

FIG. 1 illustrates a flow schematic of an embodiment for thehigh-radiant heat-flux chemical reactor implemented for biomassgasification using regenerative natural gas burners as a heat source.

FIG. 2A illustrates a block diagram of an embodiment of an examplemulti-stage synthesis gas generation system.

FIG. 2B illustrates a block diagram of an embodiment of an exampleintegrated process flow for the multi-stage synthesis gas generationsystem with its high-radiant heat-flux reactor, a Steam Methane Reformerreactor, and the associated plant.

FIG. 2C illustrates a block diagram of another embodiment of an examplemulti-stage synthesis gas generation system.

FIG. 3 illustrates a cut away view of an embodiment for the receivercavity enclosing offset and staggered reactor tubes in an embodiment ofthe high-radiant heat-flux reactor.

FIG. 4 illustrates embodiments for an entrained-flow biomass feed systemthat supplies the biomass particles in a carrier gas to the high-radiantheat-flux reactor.

FIG. 5 illustrates a flow schematic of an embodiment for the radiantheat chemical reactor configured to generate chemical products includingsynthesis gas products.

FIG. 6 illustrates a diagram of an embodiment of a high heat flux drivenbio-refinery with multiple control systems that interact with eachother.

While the invention is subject to various modifications and alternativeforms, specific embodiments thereof have been shown by way of example inthe drawings and will herein be described in detail. The inventionshould be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the invention.

DETAILED DISCUSSION

In the following description, numerous specific details are set forth,such as examples of specific chemicals, named components, connections,types of heat sources, etc., in order to provide a thoroughunderstanding of the present invention. It will be apparent, however, toone skilled in the art that the present invention may be practicedwithout these specific details. In other instances, well knowncomponents or methods have not been described in detail but rather in ablock diagram in order to avoid unnecessarily obscuring the presentinvention. Thus, the specific details set forth are merely exemplary.The specific details may be varied from and still be contemplated to bewithin the spirit and scope of the present invention.

A number of example processes for and apparatuses associated with ahigh-radiant heat-flux reactor and its associated integrated chemicalplant are described. The following drawings and text describe variousexample implementations of the design. A multiple stage synthesis gasgeneration system may include a high-radiant heat-flux reactor and aSteam Methane Reformer (SMR) reactor. The high-radiant heat-flux reactoris configured to receive biomass particles that undergo a biomassgasification reaction in the reactor at greater than 950 degrees C., viaprimarily due to the radiant heat emitted from the high-radiantheat-flux reactor, to produce reactant products including ash as well assyngas products of hydrogen and carbon monoxide coming out of an exit ofthe high-radiant heat-flux reactor. The SMR reactor is configured toreceive a methane-based gas. The SMR reactor is in parallel to andcooperates with the high-radiant heat-flux reactor to produce a highquality syngas mixture for methanol synthesis between the resultantreactant products coming from the two reactors. The SMR provides 1)hydrogen gas, 2) a hydrogen-rich syngas composition, in which a ratio ofhydrogen-to-carbon monoxide is higher than a ratio generally needed formethanol synthesis and 3) any combination of the two. The hydrogen richsyngas composition is mixed with a potentially carbon monoxide richsyngas composition, in which a ratio of carbon monoxide to hydrogen ishigher than the ratio generally needed for methanol synthesis, from thehigh-radiant heat-flux reactor to provide a required hydrogen-to-carbonmonoxide ratio for methanol synthesis. A common input into amethanol-synthesis-reactor-train coupled downstream of the SMR reactorand the high-radiant heat-flux reactor is configured to receive a firststream of the syngas components from the SMR reactor and a separatesecond stream of the syngas components from the high-radiant heat-fluxreactor. The SMR reactor control system interacts with the gasifierreactor control system based on the chemical composition feedback fromthe chemical sensors to produce a high quality syngas mixture formethanol synthesis. The high-radiant heat-flux reactor is one exampletype of biomass gasifier that may be used. One skilled in the art willunderstand parts and aspects of many of the designs discussed belowwithin this illustrative document may be used as stand-alone concepts orin combination with each other.

FIG. 1 illustrates a flow schematic of an embodiment for thehigh-radiant heat-flux chemical reactor implemented for biomassgasification using regenerative natural gas burners as a heat source.

The high-radiant heat-flux reactor 114 has at least a biomass particlefeed system, a steam supply inlet, one or more regenerative heaters, afirst set of sensors to measure a chemical composition of producedproduct gases from the high-radiant heat-flux reactor, and a gasifierreactor control system. The high-radiant heat-flux reactor 114 has adowndraft geometry with the multiple reactor tubes 102 in a verticalorientation located inside the cavity of the thermal receiver 106. Achemical reaction driven by radiant heat occurs within the multiplereactor tubes 102. Thus, the high-radiant heat-flux reactor includes twoor more vertically orientated tubes 102 within the high-radiantheat-flux reactor. The biomass particles flow inside the tubes 102 andthe one or more regenerative heaters and surfaces of high-radiantheat-flux reactor itself emit radiant heat to the outside of the two ormore tubes 102. (See FIG. 5 for an alternative biomass to tube flowarrangement) The cavity is made of highly reflective material thatdistributes radiant energy and, the receiver 106 encloses multiplereactor tubes 102 of the ultra-high heat flux high-radiant heat-fluxreactor 114. The reactor tubes 102 may be configured to pass multiplechemical reactants including 1) methane 2) natural gas, 3) steam 4)biomass particles and 5) any combination of the four, through the tubesto cause a steam methane reaction and a gasification of the biomassparticles using the thermal energy from the radiant energy.

The high-radiant heat-flux reactor 114 is driven primarily by radiativeheat transfer, and not convection or conduction. Thus, radiative heattransfer drives the high heat flux. Typical gas chemical reactors useconvection or conduction to transfer energy, and these have effectiveheat transfer coefficients between 20 W/m̂2 and 100 W/m̂2, givingeffective heat transfer fluxes below 10 kW/m̂2 (for up to a 100° C.driving temperature difference). The high radiant heat flux biomassgasifier will use heat fluxes significantly greater, at least threetimes the amount, than those found in convection driven biomassgasifiers (i.e. greater than 25 kW/m̂2). Generally, using radiation athigh temperature (>950 degrees C. wall temperature), much higher fluxes(high heat fluxes greater than 80 kW/m̂2) can be achieved with theproperly designed reactor. In some instances, the high heat fluxes canbe 100 kW/m̂2-250 kW/m̂2. For heat transfer limited reactions, the size ofcapital equipment is reduced linearly with the flux, and capital cost isgreatly reduced. Typical chemical reactors, all driven by convectionand/or conduction, simply cannot achieve these flux rates or size ofprocess equipment.

The gas-fired regenerative burners 110 under the direction of thereactor's control system supply heat energy to the high-radiantheat-flux reactor 114. The inside wall of the receiver 106 absorbs orhighly reflects the concentrated energy from the regenerative burners110 positioned along the walls of the receiver 106 cavity to causeenergy transport by thermal radiation and reflection to generally conveythat heat flux to the biomass particles inside the walls of the reactortubes. The receiver 106 inner wall absorbs or highly reflects theregenerative burners 110 to cause a radiant heat and then generallyradiatively transmits that heat to the biomass particles in the tubes ofthe solar driven high-radiant heat-flux reactor 114. An inner wall ofthe receiver 106 cavity may be made of material to allow the receiver106 cavity to be operated at high, >1200 degrees C., wall temperaturesto enable the high heat transfer rates, rapid reaction kinetics of thevery short residence time, and high selectivity of carbon monoxide andhydrogen produced from the gasification reaction for syngas.

FIG. 2A illustrates a block diagram of an embodiment of an examplemulti-stage synthesis gas generation system. A SMR reactor 18 is inparallel to and cooperates with a high-radiant heat-flux reactor 14 thatgasifies biomass and the resultant reactant products coming from the tworeactors combine to produce a high quality syngas mixture for methanolsynthesis. The SMR reactor 18 provides either 1) hydrogen, 2) ahydrogen-rich syngas composition, in which a ratio of hydrogen-to-carbonmonoxide is higher than a ratio generally needed for methanol synthesis,and 3) any combination of the two, to be mixed with a potentiallycarbon-monoxide-rich syngas composition, in which a ratio of carbonmonoxide to hydrogen is higher than the ratio generally needed formethanol synthesis, from the high-radiant heat-flux reactor 14 toprovide a required hydrogen-to-carbon monoxide ratio for methanolsynthesis. Flow of reactants through the SMR reactor 18 is used todynamically control the hydrogen-to-carbon monoxide ratio supplied tothe methanol-synthesis-reactor-train 76 while trying to maintain flow ofreactants in the high-radiant heat-flux reactor relatively steady. Note,the SMR reactor 18 includes a standard catalytic SMR reactor as well athermal SMR reactor. The thermal SMR reactor raises the temperature toabove 1200 degrees C. to decompose the CH4 methane into H2 and coke. TheSMR reactor than exposes the coke to steam H2O to gasify the coke andcreate additional syngas components of CO and H2. Coke is the solidcarbonaceous material derived from the decomposing of the methane gas.

When the SMR reactor 18 is mainly producing H2 gas then its three wayvalve routes H2 gas and other components to be combined with the syngascomponents from the high-radiant heat-flux reactor 14 after the acid gasremoval and particle filtering steps. When the SMR reactor 18 is mainlyproducing syngas components then its three way valve routes this firststream of syngas components to be combined with a second stream ofsyngas components from the high-radiant heat-flux reactor 14 to beprocessed in the acid gas removal, heat removal, potentially particlefiltering, and compression steps.

The common input into a methanol-synthesis-reactor-train 76 is coupleddownstream of the SMR reactor 18 and the high-radiant heat-flux reactor14. The common input into a methanol-synthesis-reactor-train 76 isconfigured to receive a first stream of 1) H2 gas, 2) H2, CO, CO2 gases,and any combination of these two, syngas components from the SMR reactor18 and the separate second stream of the syngas components from thehigh-radiant heat-flux reactor 14. One or more control systems monitor achemical composition feedback signal of the first stream of the syngascomponents and the second stream of the syngas components from one ormore sensors to produce a high quality syngas mixture for methanolsynthesis. The gasifier reactor control system and the SMR controlsystem may be part of the one or more control systems.

The methanol-synthesis-reactor-train 76 produces methanol from thereceived syngas components. A purge gas line from themethanol-synthesis-reactor-train 76 sends gases including CO, CO2, andCH4 over to the input of the SMR reactor 18. A feedback loop from themethanol-synthesis-reactor-train 76 provides a measurement of looppressure, purge gas rate, and composition to the one or more controlsystems.

The purge gas line may also initially contain large amounts of H2 gas.The gasifier reactor control system and the SMR control system interactto control an amount of hydrogen and carbon monoxide gases supplied tothe methanol-synthesis-reactor-train 76 to achieve a properhydrogen/carbon monoxide ratio for methanol synthesis from 1) the firststream of the syngas components from the SMR reactor 18, 2) the separatesecond stream of the syngas components from the high-radiant heat-fluxreactor 14, and 3) a flow of hydrogen gas from a recycle loop off apurge gas line coming out of the methanol-synthesis-reactor-train 76,and any of these three sources are mixed together prior to feeding thesyngas at the proper ratio into the methanol-synthesis-reactor-train 76.Thus, the methanol reactor train 76 is configured to receive syngascomponents at the common input from three sources 1) synthesis gas froma SMR reactor 18, 2) synthesis gas from the high-radiant heat-fluxreactor 14, and 3) a flow of hydrogen gas from a recycle loop off apurge gas line coming out of the methanol-synthesis-reactor-train 76.

The methane contained in the purge gas line of themethanol-synthesis-reactor-train 76 is routed as a feedstock to the SMRreactor 18. The methane may be produced in the biomass gasificationreaction in the high-radiant heat-flux reactor 14 and carried throughthe methanol production process, 2) was simply part of the entrainmentgas carrying the biomass particles being fed into the high-radiantheat-flux reactor 14 and was carried through the methanol productionprocess, or 3) in some other way was present during the biomassgasification reaction.

The proper hydrogen-to-carbon monoxide ratio of synthesis gas necessaryfor high quality methanol synthesis may be 2.0:1 to 3.0:1hydrogen-to-carbon monoxide ratio, and preferably 2.3 to 3.0 to 1. Theproper hydrogen-to-carbon monoxide ratio causes a greater overallconversion of carbon monoxide into methanol, and a per pass through themethanol synthesis train conversion of 50% or more of the carbonmonoxide into methanol.

FIG. 2C illustrates a block diagram of an embodiment of an example highradiant heat flux reactor and its design and the cooperating SMR reactorto make up a multiple stage synthesis gas generation. The Steam MethaneReformer (SMR) reactor 208 may at least have a methane-based gas feedsystem, a steam supply inlet, a second set of sensors to measure achemical composition of produced product gases from the SMR, and a SMRcontrol system. The SMR reactor 208 can be used in parallel andcooperating with the high-radiant heat-flux reactor 214 to produce ahigh quality syngas mixture for MeOH synthesis between the resultantproducts from the two reactors. The SMR 208 may provide a hydrogen richsyngas composition, in which a ratio of hydrogen-to-carbon monoxide ishigher than a ratio generally needed for methanol synthesis, to be mixedwith a potentially carbon monoxide rich syngas composition, in which aratio of carbon monoxide to hydrogen is higher than the ratio generallyneeded for methanol synthesis, from the high-radiant heat-flux reactor214 to provide a required hydrogen-to-carbon monoxide ratio for methanolsynthesis. Note, methane-based gases, such as natural gas or LPG gas,can be provided as feedstock to the SMR 208, fuel for the heaters of thehigh-radiant heat-flux reactor and potentially the heaters of the steamboilers, as well as potentially as the carrier gas for the biomassparticles. The SMR 208 receives the natural gas (CH4) adds H2O in theform of superheated steam from the boiler which yields carbon monoxide(CO) and hydrogen (H2) in generally a 3 moles of H2 for each mole of COproduced. Sometimes the endothermic steam reformation of methane can be(4CH4+O2+2H2O+energy→10H2+4CO) or (CH4+CO2+H2O+energy→2H2+2CO+H2O). Inparallel, the high-radiant heat-flux reactor 214 receives biomassparticles, such as a softwood with an example cellulose composition ofC6H10O5 and example lignin composition of C10H12O3 adds superheatedsteam (H2O), and possibly heat transfer aid particles as a feedstock togenerate large amounts of CO and H2. The syngas composition made up ofCO and H2 from the biomass gasifier goes through a gas clean up sectionto cool, pressurize, and remove any ash and other solids and any harmfulgases such as Hydrogen Sulfide and/or excess Carbon Dioxide (from theamount needed for methanol production) from the syngas to a methanolsynthesis reactor (CH3OH). The syngas composition made up of CO and H2from the SMR reactor 208 goes directly through a gas clean up section topotentially cool, pressurize, and remove harmful gases from the syngasto the methanol synthesis reactor (CH3OH).

Note, a recycle loop is in place to route methane (CH4) either 1)generated in the biomass gasification or 2) merely present in thebiomass gasification reaction in the high-radiant heat-flux reactor 214and 3) any combination of the two, over to the SMR reactor 208 from theexit of high-radiant heat-flux reactor after a quench and a particlecontrol device 209 removes any ash and other solids in a gas streamexiting the high-radiant heat-flux reactor 208. The particle controldevice may include a particle filter, centrifugal force component, anysimilar method to remove particles from a gas, and any combination ofthe three. The syngas composition made up of carbon monoxide andhydrogen exiting from the high-radiant heat-flux reactor flows to aquench and particle filter 209 to remove any ash and other solids in thesecond stream of the syngas components from the high-radiant heat-fluxreactor. A first portion but not all of the syngas from the high-radiantheat-flux reactor 214 is fed into the SMR reactor 208 to react 1) anymethane produced by the biomass gasification reaction in thehigh-radiant heat-flux reactor or 2) react any methane simply part ofthe biomass particles being fed into the high-radiant heat-flux reactor214 that is contained in the first portion of syngas components suppliedto the SMR reactor 208 from the high-radiant heat-flux reactor 214. Thegasifier reactor control system controls an amount of the first portionrouted to the SMR 208 to ensure the quality of the syngas being fed intothe methanol-synthesis-reactor-train 276. The other second portion ofthe syngas components from the high-radiant heat-flux reactor 214 is fedfurther into a gas clean up section to further cool the gas products,filter 268 out harmful contaminant gases including sulfur compounds, andcompress 274 to increase the pressure of the syngas components in thesecond stream for feeding into the common input for themethanol-synthesis-reactor-train 276.

In an embodiment, the gasifier reactor control system and the SMRcontrol system interact to alter a flow of the biomass particles throughthe high-radiant heat-flux reactor much more gradually than an alteringof a flow of the methane-based gas through the SMR reactor 208. Thus,generally the SMR control system is configured to throttle a flow of themethane-based gas and steam as reactants in the SMR reactor to use as acoarse control to maintain the proper ratio of hydrogen-to-carbonmonoxide for methanol synthesis while keeping the flow of biomassparticles entrained in a carrier gas steady through the high-radiantheat-flux reactor 214. However, the gasifier reactor control system canalso vary the amount of biomass fed into the high-radiant heat-fluxreactor 214 to the carrier gas volume to control the output syngascomposition while trying to keep temperature in specific range; but, therate of change is slower in the high-radiant heat-flux reactor 214 thanin the SMR 208.

The multiple stage synthesis gas generation system has the stream of SMRsyngas and the stream of biomass syngas meet and mix prior to being fedinto the methanol-synthesis-reactor-train 276. A common input into amethanol-synthesis-reactor-train 276 coupled downstream of the SMRreactor 208 and the high-radiant heat-flux reactor 214 is configured toreceive a first stream of the syngas components from the SMR reactor 208and a separate second stream of the syngas components from thehigh-radiant heat-flux reactor 214. The two reactors' control systemsinteract based on the chemical composition feedback from the first andsecond set of sensors at the outlet of the two reactors to produce ahigh quality syngas mixture for methanol synthesis.

In some embodiments, the common input into themethanol-synthesis-reactor-train is also configured to receive gasesfrom ballast type tanks 278 that supply and store H2 and CO gases in thetanks. The H2 and CO supply tanks may inject their respective gas inorder to rapidly compensate for small surges in the syngas compositionand overall keep the SMR flows and Biomass flows with lower ratechanges. Thus, the gasifier reactor control system and the SMR controlsystem interact to inject a flow of 1) hydrogen gas, 2) carbon monoxidegas, and 3) any of the two from the ballast tanks 278 as fine tuningcontrol over the ratio of hydrogen-to-carbon monoxide being fed to themethanol-synthesis-reactor-train 276. The multiple stage synthesis gasgeneration system may use any combination of the hydrogen rich syngascomponents from the SMR 208, carbon monoxide rich syngas components fromthe high-radiant heat-flux reactor 214, and pure CO or H2 gas from theballast tanks 278.

1) The first stream of the syngas components from the SMR reactor 208,2) the separate second stream of the syngas components from thehigh-radiant heat-flux reactor 214 and 3) the flow of hydrogen gas,carbon monoxide gas, and any of the two injected from the ballast tanks278 is mixed prior to feeding the syngas at the proper ratio into themethanol-synthesis-reactor-train 276. Thus, the methanol reactor trainis configured to receive syngas components at the common input fromthree sources 1) synthesis gas from a SMR reactor 208, 2) synthesis gasfrom the high-radiant heat-flux reactor 214, and 3) hydrogen gas orcarbon monoxide gas from small storage tanks 278. The SMR reactorcontrol system and the gasifier reactor control system interact tocontrol a chemical composition of a combined gas stream from the threesources necessary to achieve a proper hydrogen-to-carbon monoxide ratioof synthesis gas composition feed necessary for high quality methanolsynthesis, which is a 2:1 to 3:1 hydrogen-to-carbon monoxide ratio, witha preferred range of 2.3 to 3:1.

The SMR's 208 design can include a heat transfer aid for the reactionsin the SMR reactor 208. The heat transfer aids may be one or more of thefollowing: a fluidized bed or entrained flow of biomass particles, afluidized bed or entrained flow of chemically inert particles, a ceramicmonolith, ceramic tubes or aerogels, open structured packed ringsincluding Raschig rings, reticulate porous ceramic (RPC) foam, gauze orwire constructed of a high temperature-resistant material, and anycombination of these. In the SMR 208, a catalytic lining/coating may aidreaction kinetics. Note, in the biomass gasifier design, metal gauzematerials may also be used for transferring radiant heat in the gasifiertube.

An additional aspect of an example embodiment is the 1) coupling of thebiomass gasifier producing syngas eventually to a downstreamMethanol-to-Gas (MTG) plant 282 via the methanol synthesis reactor 276and 2) modifying that MTG process to recoup excess and waste methanolback into the downstream methanol-synthesis-reactor-train 276. The MTGplant 282 has a recirculation pipe to recoup methanol back into thedownstream process. The MTG process is modified by bypassing or removingthe methanol recovery section from the MTG process and piping the excessmethanol/non-converted methanol directly back into the methanolsynthesis reactor. Thus, excess methanol from the MTG process is pipeddirectly from recirculation pipe to the methanol-synthesis-reactor-train276. The MTG plant 282 produces both LPG and a finished gasoline productderived from the biomass particles fed into the high-radiant heat-fluxreactor 214 and the methane-based gas fed into the SMR 208.

In an embodiment, the on-site fuel synthesis reactor, such as the MTGplant a diesel fuel plant, etc, is geographically located on a same siteas the high-radiant heat-flux reactor and the SMR reactor. Additionally,the on-site fuel synthesis reactor is coupled downstream to receive themethanol products from the methanol-synthesis-reactor-train 276 and usethem in a hydrocarbon fuel synthesis process to create a liquidhydrocarbon fuel having an octane rating greater than 85 based on thequality of the methanol produced from the syngas components supplied tothe methanol-synthesis-reactor-train. The on-site fuel synthesis reactormay be connected to the rest of the plant facility by a pipeline that isgenerally less than 15 miles in distance. The on-site fuel synthesisreactor may supply various feedback parameters and other request to thecontrol system. For example, the on-site fuel synthesis reactor canrequest the control system to alter the H2 to CO ratio of the synthesisgas coming out of the two reactors portion of the plant and the controlsystem will do so.

Overall, the two control systems interaction with the chemicalcomposition sensors are configured to control 1) changes in a flow rateof a biomass particles being fed into the high-radiant heat-fluxreactor, 2) provides feedback to change a flow rate of natural gas andsteam into the SMR reactor, 3) directs the one or more regenerativeheaters to increase their heat input into the high-radiant heat-fluxreactor, 4) directs an increase in steam flow into the high-radiantheat-flux reactor, and 4) any combination of the four.

In an embodiment, the synthesis gas from the biomass gasificationreaction maintained by the control system can have total tarconcentrations below 200 mg Nm-3, catalyst poison concentrations below100 ppb for H2S, HCL, and NH3, and have a H2:CO ratio within the examplerange 2.3 to 2.7. These compositional concentration measurements can betaken periodically during gasifier operation through FTIR spectroscopyand gas chromatography periodically and measured with other detectors ona steady state basis. These parameters may be fed to the control systemto ensure that synthesis gas composition does not vary (+/−10%) from thedesired composition, as well as to verify that catalyst poisonconcentrations are not above deactivation thresholds for the methanolsynthesis catalyst. Ash measurements can be made one or more times dailyand mass balances can be performed to ensure that overall biomassconversion remains above threshold targets and that alkali deposits arenot being formed on the inside of the reactor.

In an embodiment, the integrated plant also contains the biomassparticle feed system to grind, pulverize, shear and any combination ofthe three biomass to a particle size controlled to an average smallestdimension size between 50 microns (um) and 2000 um. The biomass feedsystem may supply a variety of non-food stock biomass sources fed asparticles into the high-radiant heat-flux reactor. The variety ofnon-food stock biomass sources can include two or more types of biomassthat can be fed, individually or in combinational mixtures. Someexamples of non-food stock biomass sources include rice straw, cornstover, switch grass, soft woods, hard woods, non-food wheat straw,miscanthus, orchard wastes, forest thinnings, forestry wastes, energycrops, source separated green wastes and other similar biomass sources.The biomass sources can be in a raw state or in a partially torrefiedstate, as long as a few parameters, including particle size of thenon-food stock biomass and operating temperature range of the reactortubes are controlled.

The integrated plant also contains the methanol synthesis reactor train276. Methanol is a chemical with formula CH3OH (often abbreviated MeOH).It is the simplest alcohol, and is a flammable fuel and can be stored asa liquid at normal temperatures. In one example of methanol synthesis inthe methanol synthesis reactor train 276, the carbon monoxide, carbondioxide, and hydrogen in the supplied synthesis gas react on a catalystto produce methanol. A widely used catalyst is a mixture of copper, zincoxide, and alumina. As an example, at 5-10 MPa (50-100 atm) and 250° C.,it can catalyze the production of methanol from the carbon oxides andhydrogen with high selectivity according to the overall reaction:

CO+2H2→CH3OH

The methanol synthesis consumes 2 moles of hydrogen gas for every moleof carbon monoxide. One way of dealing with the excess hydrogen if itexists is to inject carbon dioxide into the methanol synthesis reactor,where it, too, reacts to form methanol according to the overallequation:

CO2+3H2→CH3OH+H2O,

-   -   Alternatively, as discussed above excess H2 in the methanol        synthesis process can be recirculated back to the H2 gas ballast        tank.

In an embodiment a methanol synthesis unit may comprise a standard shelland tube Lurgi style methanol reactor. The general process and operationis well-known with a few modifications for the integrated plant. Theprocess operates at a 4:1 recycle ratio and converts 96% of thesynthesis gas to methanol. The process may also operate at anotherexample 7.5:1 recycle ratio and conversion of 95% of the synthesis gasto methanol. The Lurgi style methanol synthesis reactor uses a boilingwater shell packed tube with a Cu/ZnO/Al203 catalyst. The exothermicheat of reaction can be removed by boiling water on the shell side ofthe reactor. The product methanol then passes through a heat exchangerto preheat the feed stream and two additional heat exchangers in orderto bring the temperature to an appropriate level for separations (66°C.). The product stream then enters a flash drum, where the un-reactedsynthesis gas can be separated from the raw methanol and water products.Some of the un-reacted synthesis gas is purged (as it contains someinert CO2 not removed by the amine system, which would build up in thesystem) and it can be recompressed by a bank of three recyclecompressors. The synthesis gas produced by the biomass gasifier isprincipally comprised of hydrogen, carbon monoxide, and some (˜5%)carbon dioxide, methane, other hydrocarbons, and water. The raw methanolis distilled from the entrained water product and fed to themethanol-to-gasoline (MTG) unit 282, where the methanol is converted togasoline and LPG.

FIG. 2B illustrates a block diagram of an embodiment of an exampleintegrated process flow for the reactor and its associated plant. In anembodiment, the integrated process with the ultra-high heat fluxchemical reactor has several major process steps: including thefollowing.

As discussed, the integrated plant also contains feed stock systems intothe high heat flux chemical reactor 814 and the SMR 808. Chemicalreactant(s) preparation 860 occurs with subsequent feeding into theultra-high heat flux chemical reactor 814. For example, this may includetorrefaction of the biomass, biomass grinding or densification,transport and offload, storage, and feeding 864. FIG. 4 goes into alittle more detail on these process steps.

A heat source is used to drive the reactions in the SMR as well as inthe ultra-high heat flux chemical reactor 814. A combination of steamand regenerative heaters may be used an example heat source.

Each set of regenerative burners may work as follows. Regeneration usesa pair of burners, which cycle to alternately heat the combustion air orrecover and store the heat from the furnace exhaust gases. When oneregenerative burner is firing, the other is exhausting the furnacegases. Exhaust gases pass through the regenerative burner body and intoa media case, which contains refractory material. The refractory mediais heated by the exhaust gases, thus recovering and storing energy fromthe flue products. When the media bed is fully heated, the regenerativeburner currently firing is turned off and begins to exhaust the flueproducts. The regenerative burner with the hot media bed begins firing.Combustion air passes through the media bed and is heated by the hotrefractory. Air preheat temperatures within 300 degrees F.-500 degreesF. of the furnace temperature are achieved resulting in exceptionallyhigh thermal efficiency.

In a solar embodiment, various heliostat field designs and operationsdrive the high radiant heat flux. Some example designs may include asolar concentrator, secondary concentrator, focused mirror array, etc.to drive high radiant heat flux reactor 814.

The biomass particles are thermally decomposed in the high radiant heatflux reactor 814 into ash, syngas components, and other products.

Quenching, gas clean up, and ash removal from biomass high radiant heatflux reactor 814 may be provided for at, for example, 868. Somenon-pilot syngas may exit the system in addition to waste heat, whichmay be recuperated at 872. Some gasses may be a waste product, whileother gasses can be compressed 874 prior to storage 878 or e.g.,methanol synthesis 876. Methanol may then be stored 880 for latermethanol to gasoline conversion 882.

In one embodiment, exit gasses from the high heat flux chemical reactor814 may be fed to SMR 808 prior to quenching 809. In another embodiment,gasses may be fed to SMR some amount of quenching, gas clean up, and ashremoval in 868. While still another embodiment might do these incombination. Thus, methane (CH4) generated in the biomass gasificationmay be supplied along with the syngas components to feed the SMRreactor.

After the chemical reaction in the high-radiant heat-flux reactoroccurs, then rapid cooling occurs to capture the molecular state of thereaction products. A quench zone 809 is located immediately downstreamof an exit of the high-radiant heat-flux reactor 114 to immediatelyquench via rapid cooling of at least the hydrogen and carbon monoxide ofthe reaction products of exiting the high-radiant heat-flux reactor 114.This achieves within 10 seconds a temperature after quenching of 800degrees C. or less, which is below a level to reduce coalescence of ashremnants of the biomass particles and a reformation reaction of thecarbon monoxide and hydrogen into larger molecules. The coolinggenerally occurs to preferably equal to or less than 400 degrees C.within the 10 seconds of exiting the high-radiant heat-flux reactor 114.At the exit of the gasification reaction zone in the reactor tubes ofthe high-radiant heat-flux reactor 114, two or more of the multiplereactor tubes form into a group at the exit and that group combinestheir reaction products and un-reacted particles from the biomassgasification into a larger pipe per group that forms a portion of thequench zone. One or more sprayers inside the larger pipe inject acooling fluid directly into the reaction product syngas stream to makethe temperature transition from the at least 900 degree C. exittemperature to less than the 400 degrees C. within the 0.1-10 seconds toprevent metal dusting corrosion of the pipe walls.

A sulfur removal sorbent, present in either the biomass gasificationprocess or initially introduced in the quench zone, reduces an amount ofsulfur present in a syngas stream exiting the quench zone in the gasclean up section 868. One or more hot particle filters to removeparticulates from the syngas stream exiting the quench zone, where theparticulates are sent to an ash-holding vessel. The products from thechemical reaction are supplied to a downstream chemical synthesis plant.

In an embodiment, hydrogen gas from a purge loop of themethanol-synthesis-reactor-train is recycled into a syngas componentfeed. The hydrogen gas is recycled back to 1) a suction of themethanol-synthesis-reactor-train, 2) the ballast tank to be stored inthe ballast tank, 3) a heater unit fed as fuel to the one or moreregenerative burners or steam heaters, and 4) any combination of thethree. Additionally, Next, methane (CH4) recovered from the methanolsynthesis 876 may be supplied back to the SMR. This provides a way todeal with methane generated in biomass gasification process. The SMRreformer may then use a catalyst on the methanol purge stream to convertpurged CHx gases to syngas or H2. This can improve the yield andmolecular weight of the produced methanol (CH3OH) from the methanolsynthesis reactor. The methanol purification reactor may be designed toprovide fuel grade methanol to the MTG unit. This creates more carboncredits. In an example embodiment, a one tower distillation system maybe used with the methanol synthesis reactor.

In an embodiment, gasoline is produced from the integrated plant. Invarious other embodiments, synthesis gas may be feed to anothertechnical application. Examples include a syngas to other chemicalconversion process. The other chemical of chemicals produced can includeliquefied fuels such as transportation liquefied fuels. Sometransportation liquefied fuels include jet fuel, DME, gasoline, diesel,and mixed alcohol, bio-char with a high sequestered amount of carbon;chemical production, electricity generation, synthetic natural gasproduction, heating oil generation, and other similar syngas basedtechnical applications. In an example hydrocarbon based fuel, e.g.,methanol, 876 may be formed from syngas. The methanol may be furtherconverted to gasoline or other fuels 882 and various products may beseparated out from the gasoline 884 or syngas. These products, e.g.,gasoline, may then be stored for later use as an energy source.

If an intermediate chemical was produced from the ultra-high heat fluxchemical reactor, that resultant product may be fed to other processesin the integrated plant. For example, a synthesis gas may be fed to atechnical application. These technical applications include syngas to atransportation liquefied fuels such as jet fuel, DME, gasoline, diesel,methanol, and mixed alcohol, bio-char with a high sequestered amount ofcarbon; chemical production, electricity generation, synthetic naturalgas production; heating oil generation; and other similar syngas basedtechnical applications.

Referring to FIG. 1, in an embodiment, one or more heat transfer aidsmay be used to heat the chemical reactant gases. The heat transfer aidmay be one or more of the following flowing particulates in the biomassparticulate stream and/or structured packing located inside each reactortube in the high-radiant heat-flux reactor. These heat radiationabsorbing materials act as heat transfer aids that can be used in thereactor tubes to increase heat transfer to reactant gases and othermaterials (operating at 20-50 times the heat flux of conventional gasphase chemical reactors). Radiation is the primary mode of heat transferto the heat transfer aids from the reactor tube walls, and conduction,convection, or some combination of the two are the secondary modes ofheat transfer from the cavity walls and reactor tubes. Additionally,heat transfer aid for reactions in the SMR reactor includes one or moreof: (1) a fluidized bed or entrained flow of biomass particles, (2) afluidized bed or entrained flow of chemically inert particles, (3) aceramic monolith, (4) ceramic tubes or aerogels, (5) open structuredpacked rings including (a) Raschig rings, (b) gauze, (c) reticulateporous ceramic (RPC) foam, or (d) wire constructed of a hightemperature-resistant material. The SMR reactor may also include acatalytic lining to aid reaction kinetics.

Note, the reactor tubes serve the dual functions of 1) segregating thebiomass gasification reaction environment from the atmosphere of thereceiver cavity and 2) transferring energy by radiation absorption andheat radiation, convection, and conduction to the reacting particles ofbiomass to drive the endothermic gasification reaction of the particlesof biomass flowing through the reactor tubes. The high heat transferrates of the reactor tubes and cavity walls allow the particles ofbiomass to achieve a high enough temperature necessary for substantialtar destruction and gasification of greater than 90 percent of thebiomass particles into reaction products including the hydrogen andcarbon monoxide gas in a very short residence time between a range of0.01 and 5 seconds.

The ultra-high heat fluxes driven by the high operating temperatures canbe suitable for driving a variety of commercially desirable reactionsincluding: Biomass gasification; Coal gasification; Steam methanereforming; Dry methane reforming; Ethylene pyrolysis, ethylenedichloride cracking (pyrolysis); Naphtha cracking, ethane cracking;Carbon black production via methane cracking; Hydrogen production viametal ferrite redox cycles; and other similar reactions.

Note, biomass gasification is an endothermic process. Energy must be putinto the process to drive it forward. Typically, this is performed bypartially oxidizing (burning) the biomass itself. Between 30% and 40% ofthe biomass must be consumed to drive the process, and at thetemperatures which the process is generally limited to (for efficiencyreasons), conversion is typically limited, giving still lower yields. Atypical theoretical gasoline yield for a standard gasification processis 50 gallons of gasoline/ton of biomass. The ultra-high heat fluxhigh-radiant heat-flux reactor 114 process uses an external source ofenergy (such as concentrated solar energy) to provide the energyrequired for reaction, so none of the biomass need be consumed toachieve the conversion. This results in significantly higher yields (100gallons of gasoline per ton). As the energy source being used to drivethe conversion is renewable and carbon free, (in the case ofconcentrated solar energy) it is eligible for carbon credits and/or willnot be adversely affected by carbon penalties in the future.

FIG. 3 illustrates a cut away view of an embodiment for the receivercavity enclosing offset and staggered reactor tubes. The thermalreceiver 306 has a cavity with an inner wall. The radiation drivengeometry of the cavity wall of the thermal receiver 306 relative to thereactor tubes 302 locates the multiple tubes 302 of the chemical reactoras offset and in a staggered arrangement inside the receiver 306. Asurface area of the cavity walls is greater than an area occupied by thereactor tubes 302 to allow radiation to reach areas on the tubes 302from multiple angles. The inner wall of the receiver 306 cavity and thereactor tubes 302 exchange energy primarily by radiation, with the wallsand tubes 302 acting as re-emitters of radiation to achieve a highradiative heat flux reaching all of the tubes 302, and thus, avoidshielding and blocking the radiation from reaching the tubes 302,allowing for the reactor tubes 302 to achieve a fairly uniformtemperature profile from the start to the end of the reaction zone inthe reactor tubes 302.

Thus, the geometry of the reactor tubes 302 and cavity wall shapes adistribution of incident radiation with these 1) staggered and offsettubes 302 that are combined with 2) a large diameter cavity wallcompared to an area occupied by the enclosed tubes 302, and additionally3) combined with an inter-tube radiation exchange between the multiplereactor tube geometric arrangement relative to each other where thegeometry. The wall is made of material that highly reflects radiation orabsorbs and re-emits the radiation. The shaping of the distribution ofthe incident radiation uses both reflection and absorption of radiationwithin the cavity of the receiver 306. Accordingly, the inner wall ofthe thermal receiver 306 is aligned to and acts as a radiationdistributor by either 1) absorbing and re-emitting radiant energy, 2)highly reflecting the incident radiation to the tubes 302, or 3) anycombination of these, to maintain an operational temperature of theenclosed ultra-high heat flux chemical reactor. The radiation fromthe 1) cavity walls, 2) directly from the regenerative burners, and 3)from an outside wall of other tubes acting as re-emitters of radiationis absorbed by the reactor tubes 302, and then the heat is transferredby conduction to the inner wall of the reactor tubes 302 where the heatradiates to the reacting particles and gases at temperatures between 900degrees C. and 1600 degrees C., and preferably above 1100 degrees C.

As discussed, the inner wall of the cavity of the receiver 306 and thereactor tubes 302 exchange energy between each other primarily byradiation, not by convection or conduction, allowing for the reactortubes 302 to achieve a fairly uniform temperature profile even thoughgenerally lower temperature biomass particles and entrainment gas enterthe reactor tubes 302 in the reaction zone from a first entrance pointand traverse through the heated cavity to exit the reaction zone at asecond exit point. This radiation heat transfer from the inner wall andthe reactor tubes 302 drives the chemical reaction and causes thetemperature of the chemical reactants to rapidly rise to close to thetemperature of the products and other effluent materials departing fromthe exit of the reactor.

A length and diameter dimensions of a gasification reaction zone of eachof the reactor tubes 302 is sized to give the very short residence timeof 0.01 second to 5 second at the gasification temperatures of at least900 degrees C., and an exit of the gasification zone in the multiplereactor tubes 302. The reaction products have a temperature from theexit of the gasification zone that equals or exceeds 900 degrees C., andthe multiple reactor tubes 302 in this chemical reactor design increaseavailable reactor surface area for radiative exchange to the biomassparticles, as well as inter-tube radiation exchange. A rapidgasification of dispersed falling biomass particulates with a resultantstable ash formation occurs within a residence time within the reactionzone in the reactor tubes 302 in the less than 5 seconds, resulting in acomplete amelioration of tar to less than 500 milligrams per normalcubic meter, and at least a 90% conversion of the biomass into theproduction of the hydrogen and carbon monoxide products.

The design reduces the required surface area of the reactor tubes 302and furnace interior, thus reducing the size, weight, and cost of thefurnace chamber (size & weight are important for tower-mounted solarapplications as well as other applications).

The temperatures of operation, clearly delineated with wall temperaturesbetween 1200° C. and 1450° C. and exit gas temperatures in excess of900° C. but not above silica melting temperatures (1600° C.) is nottypically seen in gasification, and certainly not seen in indirect(circulating fluidized bed) gasification. The potential to doco-gasification of biomass and steam reforming of natural gas which canbe done in the ultra-high heat flux chemical reactor could not be donein a partial oxidation gasifier (as the methane would preferentiallyburn).

FIG. 4 illustrate embodiments for an entrained-flow biomass feed systemthat supplies the biomass particles in a carrier gas to the chemicalreactor.

The entrained-flow biomass feed system 620 can include a pressurizedlock hopper pair 624 that feeds the biomass to a rotating metering feedscrew 622 and then into an entrainment gas pipe at the exit 626 of thelock hopper pair. The particles of the biomass are distributed intomultiple entrainment gas lines by a flow splitter 627 to feed the two ormore reactor tubes making up the chemical reactor.

In an embodiment, the high heat flux reactor and associated integratedsystem may also include the entrained-flow biomass feed system 620having one or more lock-hopper pairs 624 equipped with a singlemulti-outlet feed splitter 627 that simultaneously feeds the particlesof the biomass in pressurized entrainment gas lines into two or moretubes of the chemical reactor.

The high heat flux reactor and associated integrated system may alsoinclude a grinding system 623 and a torrefaction unit 628. Thetorrefaction unit exposes the biomass to lower temperatures 600 degreesC. and lower to pyrolyze the biomass. The grinding system 623 has agrinding device that is at least one of 1) a mechanical cutting device,2) a shearing device, 3) a pulverizing device, and 4) any combination ofthese that breaks apart the biomass, and a series perforated filters inthe entrained-flow biomass feed system. Equipment generally used forgrinding biomass includes impact mills (e.g. hammer mills), attritionmills, and kinetic disintegration mills-KDS (e.g. flail mills). A hammermill system, KDS, or similar system can be used to grind the bales(loaded by conveyer) into particles, which are to be fed into theradiant heat flux thermal gasifier. The grinding device and perforatedfilters grind the partially pyrolyzed biomass from the torrefaction unit628 to control the particle size of the biomass. The ground particleshave an average screen size between 500 microns (um) and 1000 um indiameter, and are loaded into, a silo with a standard belt conveyer orwith a positive or negative pressure pneumatic conveying system. Theground particles may also have an average screen size between 1 micron(um) and 1000 um, 1 micron (um) and 200 um, 1 micron (um) and 2000 umand various combinations. Individual fibers of biomass may for examplehave average size on the order of 3 microns. The entrained-flow biomassfeed system is feedstock flexible to be able to supply multipledifferent types of biomass without changing the feed or reactor processvia at least particle size control of the biomass and that the energysource for the chemical reaction comes from an external source, ratherthan burning the biomass itself. The torrefaction unit 628 isgeographically located on the same site as the ultra-high heat fluxchemical reactor and configured to be subject the biomass to partialpyrolysis with recouped waste heat from the chemical reaction in atemperature range of up to 300 degrees C. to make the biomass 1) brittleand easier for grinding, 2) dryer, less sticky, and easier to feed in aconveying system, 3) subject to less spoilage issues in storage as atorrefied biomass, as well as 4) produce off gases from the torrefactionprocess. The torrefaction unit 628 supplies partially pyrolyzed biomassto the grinding system 623. The torrefaction of the partially pyrolyzedbiomass reduces the energy required by the grinding device to grind thebiomass to the controlled particle size. The off gases from thetorrefaction of the biomass can be used for one or more of the 1)entrainment carrier gas, 2) an energy source for steam generation, or 3)a gas for the gas-fired regenerative burners.

The feedstock flexibility of being able to use multiple types of biomasswithout redesigning the feed and reactor process clearly gives aneconomic advantage over processes that are limited to one or a fewavailable feed stocks. By heating the reactor tubes with radiant energy(which re-radiate to the particles), the problem of generating heat forthe reaction and designing the reactor to conduct the reaction(essentially the endothermic/exothermic balancing problem) iseliminated.

FIG. 5 illustrates a flow schematic of an embodiment for the radiantheat chemical reactor configured to generate chemical products includingsynthesis gas products. The multiple shell radiant heat chemical reactor514 includes a refractory vessel 506 having an annulus shaped cavitywith an inner wall. The radiant heat chemical reactor 514 has two ormore radiant tubes 502 made out of a solid material. The one or moreradiant tubes 502 are located inside the cavity of the refractory linedvessel 506.

The exothermic heat source 510 heats a space inside the tubes 502. Thus,each radiant tube 502 is heated from the inside with an exothermic heatsource 510, such as regenerative burners, at each end of the tube 502.Each radiant tube 502 is heated from the inside with fire and gases fromthe regenerative burners through heat insertion inlets at each end ofthe tube 502 and potentially by one or more heat insertion ports locatedin between the two ends. Flames and heated gas of one or more naturalgas fired regenerative burners 510 act as the exothermic heat sourcesupplied to the multiple radiant tubes at temperatures between 900° C.and 1800° C. and connect to both ends of the radiant tubes 502. Eachtube 502 may be made of SiC or other similar material.

One or more feed lines 542 supply biomass and reactant gas into the topor upper portion of the chemical reactor 514. The feed lines 542 for thebiomass particles and steam enter below the entry points in therefractory lined vessel 506 for the radiant tubes 502 that areinternally heated. The feed lines 112 are configured to supply chemicalreactants including 1) biomass particles, 2) reactant gas, 3) steam, 4)heat transfer aid particles, or 5) any of the four into the radiant heatchemical reactor. A chemical reaction driven by radiant heat occursoutside the multiple radiant tubes 502 with internal fires. The chemicalreaction driven by radiant heat occurs within an inner wall of a cavityof the refractory lined vessel 506 and an outer wall of each of the oneor more radiant tubes 502.

The chemical reaction may be an endothermic reaction including one ormore of 1) biomass gasification (CnHm+H2O→CO+H2+H2O+X), 2) and othersimilar hydrocarbon decomposition reactions, which are conducted in theradiant heat chemical reactor 514 using the radiant heat. A steam (H2O)to carbon molar ratio is in the range of 1:1 to 1:4, and the temperatureis high enough that the chemical reaction occurs without the presence ofa catalyst.

The torrefied biomass particles used as a feed stock into the radiantheat reactor design conveys the beneficial effects of increasing andbeing able to sustain process gas temperatures of excess of 1300 degreesC. through more effective heat transfer of radiation to the particlesentrained with the gas, increased gasifier yield of generation of syngascomponents of carbon monoxide and hydrogen for a given amount of biomassfed in, and improved process hygiene via decreased production of tarsand C2+olefins. The control system for the radiant heat reactor matchesthe radiant heat transferred from the surfaces of the reactor to a flowrate of the biomass particles to produce the above benefits.

The control system controls the gas-fired regenerative burners 510 tosupply heat energy to the chemical reactor 514 to aid in causing theradiant heat driven chemical reactor to have a high heat flux. Theinside surfaces of the chemical reactor 514 are aligned to 1) absorb andre-emit radiant energy, 2) highly reflect radiant energy, and 3) anycombination of these, to maintain an operational temperature of theenclosed ultra-high heat flux chemical reactor 514. Thus, the inner wallof the cavity of the refractory vessel and the outer wall of each of theone or more tubes 502 emits radiant heat energy to, for example, thebiomass particles and any other heat-transfer-aid particles presentfalling between an outside wall of a given tube 502 and an inner wall ofthe refractory vessel. The refractory vessel thus absorbs or reflects,via the tubes 502, the concentrated energy from the regenerative burners510 positioned along on the top and bottom of the refractory vessel tocause energy transport by thermal radiation and reflection to generallyconvey that heat flux to the biomass particles, heat transfer aidparticles and reactant gas inside the chemical reactor. The inner wallof the cavity of the thermal refractory vessel and the multiple tubes502 act as radiation distributors by either absorbing solar radiationand re-radiating it to the heat-transfer-aid particles or reflecting theincident radiation to the heat-transfer-aid particles. The radiant heatchemical reactor 514 uses an ultra-high heat flux and high temperaturethat is driven primarily by radiative heat transfer, and not convectionor conduction.

FIG. 6 illustrates a diagram of an embodiment of the integrated multiplezone bio-refinery with multiple control systems that interact with eachother. In such a system, radiant heat energy may be provided to thechemical reactor 714. In this example, the chemical reactor may beheated by two or more sets of the gas-fired regenerative burners 710.

An entrainment carrier gas system supplies carrier gas for the particlesof biomass in the feed system to the chemical reactor. The otherchemical reactants, heat transfer aid particles, oxygen, and/or steammay also be delivered to the radiant tubes. As illustrated, chemicalreactants, including biomass particles, may flow into the chemicalreactor 702 and syngas flows out 712. The quench unit 709 may be used torapidly cool the reaction products and prevent a back reaction intolarger molecules.

The computerized control system may be multiple control systems thatinteract with each other. The computerized control system for thehigh-radiant heat-flux reactor is configured to send a feed demandsignal to feed system's to control an amount of 1) radiant tube sets tobe fed particles of biomass in the chemical reactor, 2) amount of gasfired regenerative burners supplying heat, 3) rate at which particulargas fired regenerative burners supply heat, and 4) any combination ofthese based on control signals and the temperature measured for thechemical reactor. The control system may rely on feedback parametersincluding temperature of the reactor as well as feed forward parametersincluding anticipated changes in heat in from the burners and heat outfrom changes in an amount of chemical reactants and carrier gas beingpassed through the radiant tubes 702.

In general, the high heat transfer rates of the radiant tubes and cavitywalls maintained by the control system allow the particles of biomass toachieve a high enough temperature necessary for substantial tardestruction and gasification of greater than 90 percent of the biomassparticles into reaction products including the hydrogen and carbonmonoxide gas in a very short residence time between a range of 0.01 and5 seconds.

The gasifier reactor control system keeps the reaction temperature inthe chemical reactor high enough based on temperature sensor feedback tothe control system to avoid the need for any catalyst to cause thechemical reaction occurring within the chemical reactor but allowing thetemperature at or near the exit to be low enough for a hygiene agentsupply line to inject hygiene agents to clean up the resultant productgas by removing undesirable compositions from the resultant product gas,promote additional reactions to improve yield, and any combination ofthese two, all while keeping the exit temperature of the chemicalreactor greater than 900 degree C. to avoid tar formation in theproducts exiting the chemical reactor.

The gasifier reactor control system may be configured to maintain thereaction temperature within the chemical reactor based upon feedbackfrom a temperature sensor at at least 1200 degrees C. to eliminate theneed for a catalyst for the chemical reactions as well as overdrive theendothermic reactions including the steam methane reforming and thesteam ethane reforming, which are equilibrium limited; and therebyimprove the equilibrium performance for the same amount of moles ofreactant feedstock, to increase both yield of resultant gaseous productsand throughput of that reactant feedstock.

The SMR control system 721 interacts with the SMR to alter a flow of themethane-based gas and steam through the SMR reactor to control a volumeof syngas components being produced.

The SMR reactor control system interacts with the gasifier reactorcontrol system to supply a proper hydrogen-to-carbon monoxide ratio ofsynthesis gas composition feed necessary for high quality methanolsynthesis, which is a 2:1 to 3:1 hydrogen-to-carbon monoxide ratio andpreferably a ratio of 2.3 to 3.0:1. The methanol-synthesis-reactor-traincoupled downstream of the SMR reactor and the high-radiant heat-fluxreactor receives a first stream of the syngas components from the SMRreactor and a separate second stream of the syngas components from thehigh-radiant heat-flux reactor. The SMR reactor control system interactswith the gasifier reactor control system based on the chemicalcomposition feedback from the first and second set of chemicalcomposition sensors to produce the high quality syngas mixture formethanol synthesis.

The control system for the torrefaction unit, catalytic converters andbiomass gasifier control the ratio and content of the syngas going tothe methanol synthesis reactor and interact with the other controlsystems in the integrated plant.

The control systems of the reactor and liquid fuel plant 720, such as aMethanol to Gasoline synthesis plant, may have bi-directionalcommunications between the chemical reactor and the liquid fuel plant,such as a methanol plant. For example, when a subset of tubes needs tobe adjusted out for maintenance or due to a failure, then the integratedplant can continue to operate with increase biomass and entrainment gasflow through the chemical reactor to keep a steady production of syngasfor conversion into a liquid fuel. Changing entrainment gas pressure inthe radiant tubes can also be used to increase/decrease the heat sinkeffect of the biomass and gas passing through the tubes.

The control system has algorithms and operational routines establishedto tolerate transient flow of syngas operation if the heat source is asolar heat source.

The control system may control the chemical reactions occurring withinthe reactor tubes via a number of mechanisms. For example, the flow rateof the chemical reactants, such as biomass particles and carrier gas,into and through the reactor tubes is controlled, along with aconcentration of each reactant flowing through the reactor tube. Thecontrol system may control each reactor tube individually, or insets/groups of for example clusters of eighteen tubes, or all of thetubes in their entirety.

Next, the various algorithms and processes for the control system may bedescribed in the general context of computer-executable instructions,such as program modules, being executed by a computer. Generally,program modules include routines, programs, objects, components, datastructures, etc. that perform particular tasks or implement particularabstract data types. Those skilled in the art can implement thedescription and/or figures herein as computer-executable instructions,which can be embodied on any form of computer readable media discussedbelow. In general, the program modules may be implemented as softwareinstructions, Logic blocks of electronic hardware, and a combination ofboth. The software portion may be stored on a machine-readable mediumand written in any number of programming languages such as Java, C++, C,etc. The machine readable medium may be a hard drive, external drive,DRAM, Tape Drives, memory sticks, etc. Therefore, the component parts,such as the transaction manager, etc. may be fabricated exclusively ofhardware logic, hardware logic interacting with software, or solelysoftware.

Some portions of the detailed descriptions above are presented in termsof algorithms and symbolic representations of operations on data bitswithin a computer memory. These algorithmic descriptions andrepresentations are the means used by those skilled in the dataprocessing arts to most effectively convey the substance of their workto others skilled in the art. An algorithm is here, and generally,conceived to be a self-consistent sequence of steps leading to a desiredresult. The steps are those requiring physical manipulations of physicalquantities. Usually, though not necessarily, these quantities take theform of electrical or magnetic signals capable of being stored,transferred, combined, compared, and otherwise manipulated. It hasproven convenient at times, principally for reasons of common usage, torefer to these signals as bits, values, elements, symbols, characters,terms, numbers, or the like. These algorithms may be written in a numberof different software programming languages. Also, an algorithm may beimplemented with lines of code in software, configured logic gates insoftware, or a combination of both.

It should be borne in mind, however, that all of these and similar termsare to be associated with the appropriate physical quantities and aremerely convenient labels applied to these quantities. Unlessspecifically stated otherwise as apparent from the above discussions, itis appreciated that throughout the description, discussions utilizingterms such as “processing” or “computing” or “calculating” or“determining” or “displaying” or the like, refer to the action andprocesses of a computer system, or similar electronic computing device,that manipulates and transforms data represented as physical(electronic) quantities within the computer system's registers andmemories into other data similarly represented as physical quantitieswithin the computer system memories or registers, or other suchinformation storage, transmission or display devices.

While some specific embodiments of the invention have been shown theinvention is not to be limited to these embodiments. For example, therecuperated waste heat from various plant processes can be used topre-heat combustion air, or can be used for other similar heating means.Regenerative gas burners or conventional burners can be used as a heatsource for the furnace. The source of the radiant heat may be one ormore of 1) solar energy, 2) gas-fired regenerative burners, 3) nuclearpower, 4) electric heaters and 5) any combination of these four. Thehigh radiant heat flux reactor may be used as a biomass gasifier butother types of biomass gasifier are useable as well. The high radiantheat flux reactor can be used for any type of endothermic reaction inany aspect of the chemical industry discussed herein. Biomass gasifierreactors other than a radiant heat chemical reactor may be used. TheSteam Methane Reforming may be/include a SHR (steam hydrocarbonreformer) that cracks short-chained hydrocarbons (<C20) includinghydrocarbons (alkanes, alkenes, alkynes, aromatics, furans, phenols,carboxylic acids, ketones, aldehydes, ethers, etc, as well as oxygenatesinto syngas components. The invention is to be understood as not limitedby the specific embodiments described herein, but only by scope of theappended claims.

1. A multiple stage synthesis gas generation system, comprising: ahigh-radiant heat-flux reactor configured to receive biomass particlesthat undergo a biomass gasification reaction in the reactor at greaterthan 950 degrees C., via primarily due to a radiant heat emitted fromthe high-radiant heat-flux reactor, to produce reactant productsincluding ash and syngas products of hydrogen and carbon monoxide comingout of an exit of the high-radiant heat-flux reactor; a Steam MethaneReformer (SMR) reactor configured to receive a methane-based gas, wherethe SMR reactor is in parallel to and cooperates with the high-radiantheat-flux reactor to produce a high quality syngas mixture for methanolsynthesis between the resultant reactant products coming from the tworeactors, wherein the SMR provides 1) hydrogen gas, 2) a hydrogen-richsyngas composition, in which a ratio of hydrogen-to-carbon monoxide ishigher than a ratio generally needed for methanol synthesis, and 3) anycombination of the two, to be mixed with a potentiallycarbon-monoxide-rich syngas composition, in which a ratio of carbonmonoxide to hydrogen is higher than the ratio generally needed formethanol synthesis, from the high-radiant heat-flux reactor to provide arequired hydrogen-to-carbon monoxide ratio for methanol synthesis; and acommon input into a methanol-synthesis-reactor-train coupled downstreamof the SMR reactor and the high-radiant heat-flux reactor that isconfigured to receive a first stream of the syngas components from theSMR reactor and a separate second stream of the syngas components fromthe high-radiant heat-flux reactor, where one or more control systemsmonitor a chemical composition feedback signal of the first stream ofthe syngas components and the second stream of the syngas componentsfrom one or more sensors to produce a high quality syngas mixture formethanol synthesis.
 2. The multiple stage synthesis gas generationsystem of claim 1, where the high-radiant heat-flux reactor has abiomass particle feed system, a first steam supply inlet, one or moreregenerative or recuperative heaters, a first set of sensors to measurea chemical composition of produced product gases from the high-radiantheat-flux reactor, and a gasifier reactor control system to cause thebiomass gasification reaction of the biomass particles at greater than950 degrees, the SMR reactor has a methane-based gas feed system, asecond steam supply inlet, a second set of sensors to measure a chemicalcomposition of produced product gases from the SMR reactor, and a SMRcontrol system, and both the SMR control system and the gasifier reactorcontrol system are part of the one or more control systems, and thecommon input into the methanol-synthesis-reactor-train is alsoconfigured to receive gases from a purge line exiting themethanol-synthesis-reactor-train, wherein the gasifier reactor controlsystem and the SMR control system interact to control an amount ofhydrogen and carbon monoxide gases supplied to themethanol-synthesis-reactor-train to achieve a proper hydrogen/carbonmonoxide ratio for methanol synthesis from 1) the first stream of thesyngas components from the SMR reactor, 2) the separate second stream ofthe syngas components from the high-radiant heat-flux reactor and 3) aflow of hydrogen gas from a separator off a purge gas line coming out ofthe methanol-synthesis-reactor-train, and any of these three sources aremixed together prior to feeding the syngas at the proper ratio into themethanol-synthesis-reactor-train.
 3. The multiple stage synthesis gasgeneration system of claim 1, wherein a gasifier reactor control systemand a SMR control system are part of the one or more control systems andinteract to alter a flow of the biomass particles through thehigh-radiant heat-flux reactor much more gradually than an altering of aflow of the methane-based gas through the SMR reactor; and thus, wherethe SMR control system is configured to throttle a flow of themethane-based gas and steam as reactants in the SMR reactor to use as acoarse control to maintain the proper ratio of hydrogen-to-carbonmonoxide for methanol synthesis while keeping the flow of biomassparticles entrained in a carrier gas steady through the high-radiantheat-flux reactor.
 4. The multiple stage synthesis gas generation systemof claim 1, wherein the syngas composition made up of carbon monoxideand hydrogen exiting from the high-radiant heat-flux reactor flows to aparticle control device to remove any ash and other solids in the secondstream of the syngas components from the high-radiant heat-flux reactor,and any methane coming out from the methanol-synthesis-reactor-trainpurge stream is fed as a feedstock into the SMR reactor, where themethane was produced in the biomass gasification reaction in thehigh-radiant heat-flux reactor or 2) was simply part of the entrainmentgas carrying the biomass particles being fed into the high-radiantheat-flux reactor, where the gasifier reactor control system, and wherethe syngas components from the high-radiant heat-flux reactor is fedfurther into a gas clean up section to cool the gas products, filter outharmful contaminant gases including sulfur compounds, and compress toincrease the pressure of the syngas components for feeding into thecommon input for the methanol-synthesis-reactor-train.
 5. The multiplestage synthesis gas generation system of claim 1, wherein thehigh-radiant heat-flux reactor includes two or more tubes that areheated from the inside of the tubes and have biomass flowing on anoutside of the tubes.
 6. The multiple stage synthesis gas generationsystem of claim 3, where the methanol reactor train is configured toreceive syngas components at the common input from three sources 1)synthesis gas from a SMR reactor, 2) synthesis gas from the high-radiantheat-flux reactor, and 3) a flow of hydrogen gas from a separator off apurge gas line coming out of the methanol-synthesis-reactor-train,wherein the SMR reactor control system and the gasifier reactor controlsystem interact to control a chemical composition of a combined gasstream from the three sources necessary to achieve a properhydrogen-to-carbon monoxide ratio of synthesis gas composition feednecessary for high quality methanol synthesis, which is a 2.0:1 to 3:1hydrogen-to-carbon monoxide ratio.
 7. The multiple stage synthesis gasgeneration system of claim 6, wherein the ratio is 2.3 to 3.0 to 1 thatcauses a greater overall conversion of carbon monoxide into methanol anda per pass through the methanol synthesis train conversion of 50% ormore of the carbon monoxide into methanol, and wherein the high-radiantheat-flux reactor includes two or more vertically orientated tubeswithin the high-radiant heat-flux reactor, and where the biomassparticles flow inside the tubes and the one or more regenerative heatersand surfaces of high-radiant heat-flux reactor itself emit radiant heatto the outside of the two or more tubes.
 8. The multiple stage synthesisgas generation system of claim 1, wherein hydrogen gas from a purge gasline of the methanol-synthesis-reactor-train is recycled into a syngascomponent feed to a suction of the methanol-synthesis-reactor-train andany methane in the purge gas line of themethanol-synthesis-reactor-train is routed as a feedstock to the SMRreactor.
 9. The multiple stage synthesis gas generation system of claim1, further comprising: an on-site fuel synthesis reactor that isgeographically located on a same site as the high-radiant heat-fluxreactor and the SMR reactor, where the on-site fuel synthesis reactor iscoupled downstream to receive the methanol products from themethanol-synthesis-reactor-train and use them in a hydrocarbon fuelsynthesis process to create at least one of a liquid hydrocarbon fuel, ablend stock fuel, and a chemical feedstock, which includes gasoline,aviation fuel, middle distillate, olefins, dimethyl ether, and otheroxygenated hydrocarbons.
 10. The multiple stage synthesis gas generationsystem of claim 1, further comprising: a recycle loop to route methane(CH4) either 1) generated in the biomass gasification or 2) merelypresent during the biomass gasification reaction in the high-radiantheat-flux reactor and 3) any combination of the two, over to the SMRreactor from the exit of the methanol-synthesis-reactor-train.
 11. Themultiple stage synthesis gas generation system of claim 3, wherein thetwo control systems interaction with the sensors are configured tocontrol 1) changes in a flow rate of a biomass particles being fed intothe high-radiant heat-flux reactor, 2) provides feedback to change aflow rate of natural gas and steam into the SMR reactor, 3) directs theone or more regenerative heaters to increase their heat input into thehigh-radiant heat-flux reactor, and 4) any combination of the three. 12.The multiple stage synthesis gas generation system of claim 1, whereinthe SMR includes a heat transfer aid for reactions in the SMR reactor,where the heat transfer aid includes one or more of: (1) a fluidized bedor entrained flow of biomass particles, (2) a fluidized bed or entrainedflow of chemically inert particles, (3) a ceramic monolith, (4) ceramictubes or aerogels, (5) open structured packed rings including any of (a)Raschig rings, (b) gauze, (c) wire constructed of a hightemperature-resistant material, and (d) reticulate porous ceramic (RPC)foam, wherein the SMR reactor includes a catalytic lining to aidreaction kinetics.
 13. The multiple stage synthesis gas generationsystem of claim 1, wherein after the gasification reaction in thehigh-radiant heat-flux reactor occurs, then a rapid cooling occurs tocapture a molecular state of the reaction products in a quench zone thatis located immediately downstream of the exit of the high-radiantheat-flux reactor to immediately quench via rapid cooling of at leastthe hydrogen and carbon monoxide of the reaction products of exiting thehigh-radiant heat-flux reactor, where the quench achieves within tenseconds a temperature of 850 degrees C. or less, which is below a levelto reduce coalescence of ash remnants of the biomass particles and areformation reaction of the carbon monoxide and hydrogen into largermolecules.
 14. The multiple stage synthesis gas generation system ofclaim 1, wherein the high-radiant heat-flux reactor system includes thebiomass particle feed system to grind, pulverize, shear and anycombination of the three biomass to a particle size controlled to anaverage smallest dimension size between 1 micron (um) and 2000 um, andwherein the biomass feed system may supply a variety of non-food stockbiomass sources fed as particles into the high-radiant heat-flux reactorand wherein the variety of non-food stock biomass sources can includetwo or more types of biomass that can be fed, individually or incombinational mixtures.
 15. The multiple stage synthesis gas generationsystem of claim 14, wherein the gasifier reactor control systemmaintains the reaction conditions in the high-radiant heat-flux reactorand a combination of the controlled particle size, temperature beinggreater than 950 degrees C. within the reactor at an exit of thereactor, and designed residence time within the reactor to cause a rapidgasification of dispersed biomass particulates with a resultant stableash formation within a residence time in the less than 5 seconds,resulting in a complete amelioration of tar to less than 500 milligramsper normal cubic meter, and at least a 80% conversion of the biomassparticles into the production of the hydrogen and carbon monoxideproducts.
 16. A method of multiple stage synthesis gas generation systemin an integrated plant, comprising: providing a high-radiant heat-fluxreactor to conduct a biomass gasification reaction on biomass particlesto cause the production of at least carbon monoxide, hydrogen, and ash;providing a Steam Methane Reformer (SMR) reactor, the SMR reactor inparallel and cooperating with the high-radiant heat-flux reactor toproduce a high quality syngas mixture for methanol synthesis between theresultant products from the two reactors wherein the SMR provideshydrogen rich syngas to be mixed with the potentially carbon monoxiderich syngas from the high-radiant heat-flux reactor to provide therequired hydrogen-to-carbon monoxide ratio for methanol synthesis;immediately quenching the products from the biomass gasificationreaction in the high-radiant heat-flux reactor and then removing ash andother solids from the products
 17. The method of claim 16, furthercomprising controlling the volume of hydrogen/carbon monoxide comingfrom the SMR reaction by throttling when mixing with the reactionproducts of the biomass reaction to achieve the proper hydrogen/carbonmonoxide ratio for methanol synthesis such that altering the flow of thebiomass through the high-radiant heat-flux reactor occurs more graduallythan altering the flow of methane-based gas through the SMR.
 18. Themethod of claim 16, further comprising: keeping the temperature withinthe high-radiant heat-flux reactor within a specific range and varyingthe amount of biomass fed into high-radiant heat-flux reactor to thecarrier gas volume to control the output syngas composition and whereinthe high-radiant heat-flux reactor includes internally heated tubes andbiomass flowing on the outside of the tubes.
 19. The method of claim 16,further comprising: providing a methanol reactor train that receivessyngas from a common input of 1) synthesis gas from a SMR reactor, 2)synthesis gas from the high radiant heat flux and 3) a flow of hydrogengas from a separator off a purge gas line coming out of themethanol-synthesis-reactor-train; and controlling the chemicalcomposition of the combined gas streams from the three sources necessaryto achieve the proper hydrogen-to-carbon monoxide ratio of synthesis gascomposition feed necessary for high quality methanol synthesis, which isa 2.0:1 to 3.0:1 hydrogen-to-carbon monoxide ratio.
 20. The method ofclaim 19, wherein flow of reactants through the SMR reactor is used todynamically control the hydrogen-to-carbon monoxide ratio supplied tothe methanol-synthesis-reactor-train while trying to maintain flow ofreactants in the high-radiant heat-flux reactor relatively steady.